How to cover a simple bend in a cable tray

A simple bend in a cable tray can be covered or finished using pre-fabricated bends, custom gussets, or protective caps to ensure safety and maintain cable integrity.Using Pre-Fabricated BendsThe easiest method is to use a pre-manufactured 90-degree or angled bend that matches the tray type and size. These bends are designed to fit seamlessly with straight sections of the tray, providing a smooth path for cables and maintaining structural integrity without additional modifications .Creating a Custom BendIf a pre-fabricated bend is not available, you can create a custom bend using the following steps:Mark the Bend Location: Measure and mark the exact point where the bend is required on the tray .Remove Tray Lips: For a flat 90° bend, remove part of the tray lip using a hand grinder or file to allow the tray to bend without deforming .Cut and Flatten: Cut along the center line carefully and flatten the tray lip at the bend point using a blunt object .Bend and Secure: Bend the tray to the desired angle and bolt the two parts together. Measure the internal edges to create a gusset if needed, then attach it to reinforce the bend .Smooth the Edges: Ensure all cut edges are smooth to prevent cable damage.Covering and Protecting the BendOnce the bend is formed, it is important to cover or protect the exposed edges:Gussets: Use a gusset piece to bridge the internal gap of the bend, providing structural support and a smooth surface for cables .Rubber or Plastic Caps: For wire mesh trays, protective caps can be placed over cut ends to prevent injury and protect cables .Bolt Cutters and Zinc Layer: When working with wire mesh trays, using a bolt cutter can form a protective zinc layer on cut ends, which helps prevent corrosion and maintains safety .Safety ConsiderationsAlways wear protective gloves and eye protection when cutting or grinding metal trays.Ensure the bend is smooth and free of sharp edges to avoid damaging cables.Verify that the bend maintains the required angle and alignment for proper cable routing. By following these methods, you can effectively cover and protect a simple bend in a cable tray, whether using pre-fabricated components or custom-fabricated bends, ensuring both safety and functionality .